Polymer composition for improved grade plastics from recycled material

ABSTRACT

A polymer composition including
         60-80 wt % of a recycled polypropylene;   10-35 wt % of a recycled polyethylene;   5-20 wt % of a polyolefin elastomer (POE);   0.1-10 wt % styrene ethylene butylene styrene block copolymer (SEBS);   wherein the wt % is relative to the total weight of the polymer composition;   wherein the polymer composition includes at least 11 wt % of polyolefin elastomer and styrene ethylene butylene styrene block copolymer.

FIELD OF THE INVENTION

The present invention relates to an improved polymer compositioncontaining a high amount of recycled polypropylene (PP) and polyethylene(PE). As well as to the use of such polymer composition in themanufacturing of articles, the articles manufactured from said polymercomposition and to the process of preparing such polymer composition.

BACKGROUND OF THE INVENTION

The omnipresence of plastic packaging and the importance ofenvironmental policy have led to the increased importance of recycledplastic materials.

The recycling of paper, textiles, glass or metals is already carried outon a large scale, whether by separate collection or by sorting of therecyclate. The recycling of plastic waste and re-use of plastics is alsoincreasing.

Virgin polymer composition replacement is considered to represent theonly way forward to solve the global plastic waste problem, to stop thedepletion of natural resources, and to facilitate a circular economy.

To-date recycled polymer compositions are available, in the form offlakes or granules, that are obtained from the collection of polyolefinpackaging, containers or films are available on the market, wherein thepolyolefins are present within the recycled polymer composition at a lowpercentage of between 5-8 wt % and the remaining between 92-95 wt % ofthe polyolefins are made-up of virgin polyolefins.

The aim of the invention is to produce a polymer composition containinga high amount of recycled polyolefin that can compete with virginmaterial with respect to product performance and price. To-date polymercompositions of recycled polyolefin blends cannot compete with theimpact strength and stiffness of virgin polyolefin blends.

The currently available polymer compositions of polyolefins suffer frompolystyrene contaminants, rubber contaminants and variability and poorconsistency of the recycled plastic feeds. Subsequently the currentlyavailable polymer compositions of polyolefins have a low impact strengthand stiffness when compared to virgin materials.

It is a further aim of the invention to produce a polymer composition ofrecycled polyolefins that can be used to manufacture blow moulded andinjection moulded packaging as well as durable products without need forfurther blending with virgin polyolefin materials.

There is currently no known polymer composition containing a highpercentage of recycled polyolefins (at least 75 wt %, preferably 80 wt%, more preferably 85 wt %, of polyolefins from recycling, within thepolymer composition) with properties fit for consumer products,manufactured through processes such as for example blow-moulding andinjection moulding, and with a high impact strength and stiffness. Thewt % is relative to the total weight of the polymer composition, if notstated otherwise.

The source of materials for polymer composition of recycled polymermaterial can be food and household goods packaging, e.g. polyolefinplastics (such as for example PP and PE) that can be contaminated byother polymer families, such as for example styrene polymers.

Styrene polymers are used in the production of packaging and containersfor perishable foods, in the form of polystyrene (PS); in the productionof industrial packaging, in the form of acrylonitrile butadiene styrene(ABS); in the production of packaging, containers and as fillers forpackaging and containers, in the form of expanded polystyrene (EPS).Thus, styrene polymers need to be removed during the processing of theto be recycled materials. A complete removal is technically andeconomically not possible. But any remaining residual polystyrene has asignificant negative impact on the mechanical properties of the recycledpolyolefins composition. EPS for example accelerates radical generationand therewith material degradation, and renders articles manufacturedmore brittle. Further, polyethylene terephthalate (PET) has a negativeimpact on the mechanical properties of the polymer composition.

Polyvinyl chloride (PVC), polyvinylidene chloride (PVDC) and styrenepolymers are considered to be only partially compatible with PP and PE,especially when recycling to produce a new recycled polyolefin blendusing extrusion.

The coexistence of significant percentages of other polymer contaminantstogether with the recycled polyolefins coming from recycled packaginghas to be accepted, in order to make available a polymer flake orgranule from recycling at competitive costs with respect to virginpolyolefin materials.

An additional problem in the use of recycled polyolefin polymercompositions, particularly from recycled packaging, is the variabilityand poor consistency of the polymer in the feed. Thus, this variabilityand poor consistency is also found within the regenerated granule orflake and produced articles. This variability and poor consistency ofthe polymer leads to an aesthetically unacceptable surface andinconstant mechanical properties of the final products. At the sametime, the use of said granules in injection moulding processes islimited or prevented by at least one of the following defects extremebrittleness, low impact strength and stiffness, of granules or flakesand products obtained from recycling.

SUMMARY OF THE INVENTION

It is an object of the present invention to solve at least one of theabove-listed problems. Further object of the invention is to obtain apolymer composition that can be efficiently used in the mouldingprocesses, particularly injection moulding, wherein the percentage ofrecycled polyolefins within the polymer composition is high, i.e. atleast 70 wt %, preferably 75 wt %, more preferably 80 wt %, mostpreferably 85 wt % of polyolefins from recycling, in the polymercomposition. The polymer composition can be used to produce flakes orgranules and products at competitive costs with high impact strength andstiffness, when compared to virgin polyolefin products. The polymercomposition can produce a product that has a high impact strength(Charpy) and optionally has increased stability upon exposure to theenvironment, such as for example temperature, humidity or sun exposure.

The invention relates to a polymer composition comprising:

60-80 wt % of a recycled polypropylene;

10-35 wt % of a recycled polyethylene;

5-20 wt % of a polyolefin elastomer (POE);

0.1-10 wt % styrene ethylene butylene styrene block copolymer (SEBS);

wherein the wt % is relative to the total weight of the polymercomposition;

wherein said polymer composition comprises at least 11 wt % ofpolyolefin elastomer and styrene ethylene butylene styrene blockcopolymer.

The recycled PP and recycled PE polymer composition according to theinvention has an increased impact strength compared to standard recycledPP and recycled PE polymer compositions, despite contamination withother polymers. The tensile modulus stays on a high level, while theimpact strength has been improved. The polymer composition of theinvention can have a melt flow rate sufficient for efficient injectionmoulding. Further, the invention can allow for controlled shrinkageduring and/or after processing.

The invention has at least one of the following advantages usability ofthe polymer composition for moulding, especially injection moulding,reduced need for peroxides, increased impact strength relative to otherrecycled PP and recycled PE polymer compositions.

DETAILED DESCRIPTION OF THE INVENTION

The polymer composition preferably comprises a high amount of a recycledpolypropylene and recycled polyethylene, with added styrene ethylenebutylene styrene block copolymer and polyolefin elastomer; andoptionally additives.

Recycled Polypropylene

The PP raw material comprises plastic waste, predominantly post-consumerwaste (PCW) PP packaging waste, such as for example detergent andshampoo bottles, dairy pots and meat trays, etc. The PP raw materialwaste can be pre-sorted by waste management companies. One suitable PPsource can for example be the waste material collected under the DSD 324(05-2012) and DSD 324-1 standard (03-2018).

The PP DSD 324 (05-2012) raw material can comprise at least one of thefollowing used, residue-drained, rigid, system-compatible items made ofpolypropylene, e.g. bottles, cups and trays, incl. secondary componentssuch as lids, labels etc. The PP DSD 324 (05-2012) raw material cancomprise a maximum total amount of impurities 6% by mass. The impuritiesin the PP DSD 324 (05-2012) raw material can comprise other metal items<0.5% by mass, rigid PE items <1% by mass, expanded plastics inc. EPSitems <0.5% by mass, plastic films <2% by mass and other residues <3% bymass. Further examples of impurities in PP DSD 324 (05-2012) rawmaterial can comprise glass, paper, board, cardboard, compositepaper/cardboard materials (e.g. liquid packaging boards), aluminisedplastics, other materials (e.g. rubber, stones, wood, textiles, nappies)and compostable waste (e.g. food, garden waste).

A second standard for recycled PP is the PP DSD 324-1 standard(03-2018). This standard is very comparable to the PP DSD 324 standarddiscussed above, except that the recycled PP can contain more filmmaterial, up to about 10 wt %. This film material comprises bothrecycled PP film (such as for example bioriented PP (BOPP)) PE film. ThePP DSD 324-1 standard (03-2018) raw material can comprise a maximumtotal amount of impurities 4% by mass. The impurities in the PP DSD324-1 standard (03-2018) raw material can comprise other metal items<0.5% by mass, rigid PE items <1% by mass, expanded plastics inc. EPSitems <0.5% by mass, paper, cardboard, carton, composite paper/cardboardmaterials (e.g. liquid packaging boards)<1% by mass, other residues <3%by mass. Further examples of impurities in PP DSD 324-1 standard(03-2018) raw material can comprise glass, aluminised plastics, othermaterials (e.g. rubber, stones, wood, textiles, nappies) and compostablewaste (e.g. food, garden waste).

Examples of recycled PP are EXPP152A (MFR 15)/300P and EXPP163A (MFR50)/300T.

Optical sorting can also be used to remove unwanted polymers, butpolystyrene or polyethylene contamination in the feed still occurs andhas a substantial negative impact on the mechanical properties of therecycled polymer composition.

PP is available in three different varieties, PP homopolymers (PPh), PPrandom copolymer (PPr) and PP impact copolymer (or heterophasic PPcopolymer, PPc).

The waste material can for example be characterized as originating fromfollowing sources (a) extrusion sheet and film material, mostly PPhomopolymers (PPh) and PP random copolymers (PPr), virtually withoutrubber (such as for example biaxially-oriented polypropylene (BOPP));and (b) injection moulded material, which are a mix of PP homopolymer(PPh), PP random copolymers (PPr) and impact copolymer (PPc), containingabout 15 wt % rubber.

The recycled PP can contain approximately half of packaging material(BOPP) and half of rubber-containing injection moulded material. Thisinjection moulded material can contain rubbers, such as for exampleC2-C3 rubber, thermoplastic elastomers (TPE), ethylene propylene dienemethylene (EPDM) or ethylene propylene rubber (EPR).

The resulting mix of the recycled PP itself used in the polymercomposition can for example have a rubber content of between 1.5-12 wt %(rubber from rubber-containing injection moulded material; wherein wt %is relative to the total amount of the mix of the recycled PP). On topof the rubber from the rubber-containing injection moulded materialadditional rubber has been added to the polymer composition. Theadditional rubber comprises at least POE and SEBS.

The recycled PP content of the polymer composition is preferably made-upof between 25-75 wt % BOPP and between 25-75 wt % rubber-containinginjection moulded material; wherein wt % is relative to the total amountof recycled PP.

The recycled PP is present between 60-80 wt %, preferably 60-77.5 wt %,more preferably between 62-75 wt %, within the polymer composition;wherein wt % is relative to the total weight of the polymer composition.

Recycled Polyethylene

The recycled PE comprises PE waste collected under the DSD 329 standard(April/2009), PE waste based on UK milk bottles, PE waste based onFrench milk bottles, PE vessels having a volume of 5 litres or more andbeing cleaned in accordance with environmental specifications or PEextrusion pipes. Further PE sources are not excluded.

The recycled PE DSD 329 standard (April/2009) raw material can compriseat least one of the following used, completely emptied, rigid,system-compatible articles made of polyethylene, e.g. bottles anddishes, incl. packaging parts such as caps, lids, labels etc. Therecycled PE DSD 329 standard (April/2009) raw material raw material cancomprise a maximum total amount of impurities 6% by mass. The recycledPE DSD 329 standard (April/2009) raw material can comprise other metalarticles <0.5 mass %, dimensionally stable PP articles <3 mass %, foamedplastics ind. EPS articles <0.5 mass %, plastic films <5 mass % andother residual materials <3 mass %. Further examples of impurities inrecycled PE DSD 329 standard (April/2009) raw material can compriseglass, paper, cardboard, composite paper/cardboard materials (e.g.beverage cartons), aluminised plastics, other materials (e.g. rubber,stones, wood, textiles, nappies) and compostable waste (e.g. food,garden waste).

An example of recycled PE from DSD 329 standard (April/2009) rawmaterial is HDPE 5404 0216.

The recycled PE preferably comprises recycled High-Density Polyethylene(HDPE) to at least 90 wt %, more preferably at least 92 wt %, mostpreferably at least 95 wt %.

The recycled PE collected according to the DSD 329 standard contains avariety of contaminants which can have a negative effect when used inblow-moulding. These are removed by means of a plurality of steps,including cleaning steps, washing steps and sorting steps. The recycledPE can for example be split into different streams, such as a filmfraction (PE+EPS), alight fraction and a dark fraction. The PE recyclatemay preferably comprise 0-6 wt %, more preferably between 1-5 wt %, mostpreferably between 3-4.5 wt % polypropylene and up to 1 wt % polystyrenecontaminants, wherein wt % is relative to the total amount of recycledPE.

The recycled PE preferably has a density in the range of approximately0.94-0.97 g/cm³ and can have different molecular weight distributions. Astandard Gaussian distribution of the molecular weight is called‘monomodal’. A specific and broad distribution is called ‘bimodal’. ThePE may have an in-between modality of ‘1.5×monomodal’.

The MFR of the PE (2.16 kg, 190° C.) may preferably be in the range of0.1-0.5 which is suitable for blow moulding materials. The PE may be alight recyclate. The recycled PE may preferably have a L* value between71-80, a* value between −6 to 0 and a b* value between 0-12; asdetermined on the basis of CIELAB.

The recycled PE may preferably have an MFR 2.16 kg, 230° C. (g/10 min)of between 0.4-0.9, more preferably between 0.45-0.85.

The recycled PE may preferably have an MVR 2.16 kg, 230° C. (ml/10 min)of between 0.3-1.3, more preferably between 0.6-1.0. The recycled PE maypreferably have a charpy (23° C., kJ/m²) of between 10-20, morepreferably between 12-17. The recycled PE may preferably have a density(kg/m³) of between 850-1050, more preferably between 900-1000. Therecycled PE may preferably have a Tensile modulus (MPa) of between1030-1230, more preferably between 1080-1180.

Standard virgin PP and virgin PE blend polymer compositions have aTensile stiffness between 600-1300 MPa and charpy Notched Impactstrength of between 23-50 kJ/m². The mechanical properties of thepolymer composition according to the present invention are very close tothe values of the mechanical properties of virgin materials.

The recycled PE is present between 10-35 wt %, preferably 12-35 wt %,more preferably between 15-25 wt %, within the polymer composition,wherein wt % is relative to the total weight of the polymer composition.

The recycled PE is preferably present in the polymer composition at aweight ratio between of 3:1-1:1 with the POE, within the polymercomposition.

Additional Rubber

Two types of rubber have been surprisingly found to improve the impactstrength of the final product produced using the polymer composition ofthe invention, while keeping up high tensile modulus. The first type isPOE and the second rubber used is SEBS rubber.

The polymer composition preferably has a total rubber content of between5-24 wt %, more preferably between 8-20 wt %, most preferably between11-18 wt %, as determined with cold xylene solubles (CXS).

The polymer composition comprises at least 11 wt %, preferably at least12 wt % of polyolefin elastomer and styrene ethylene butylene styreneblock copolymer.

Polyolefin Elastomer

The polymer composition comprises a polyolefin elastomer (POE) which isan ethylene alpha olefin copolymer. Examples of POE are C2-C4copolymers, C2-C6 copolymers and C2-C8 copolymers.

The POE can preferably be a C2-C6 copolymer or a C2-C8 copolymer withbetween 70-80 wt % ethylene, more preferably between 73-78 wt %, mostpreferably between 74-77 wt %; wherein wt % is relative to the POE.

The POE used in the invention preferably comprises an ethylene (C2)octene (C8) metallocene rubbers with a blocky structure.

The POE preferably has a density of between 0.85-0.89, more preferablybetween 0.855-0.885, most preferably between 0.86-0.875.

The POE preferably has an MFR of between 0.3-1, more preferably between0.4-0.8, most preferably between 0.45-0.7 (190° C., 2.16 kg).

The added C2-C8 rubber can match the C2-C3 rubber in the injectionmoulded materials. This has a surprisingly positive effect on the impactstrength of the polymer composition.

The addition was further found to also surprisingly increase thestiffness. The C2-C8 rubber can also increase flow or allow forreduction in use of the peroxide in the process.

The POE is preferably selected from the group of Infuse or Engagepolymers, such as for example infuse 9107, Infuse 9077 and EngageXLT8677.

The POE is present at between 5-20 wt %, preferably 6-20 wt %, morepreferably between 6-15 wt %, within the polymer composition.

Styrene Ethylene Butylene Styrene Block Copolymer

The second type of rubber of the polymer composition is a SEBS rubber.

SEBS rubbers are (partly) hydrogenated styrene-butadiene-styrene blockcopolymers. They belong to the family of styrenic block copolymers(SBC). These polymers are triblock copolymers, having styrene at bothextremities of the polymer chain with an internal polybutadiene,polyisoprene or hydrogenated polybutadiene or polyisoprene block.

SEBS copolymers are commercially available, for example under thetradenames of Kraton and Tuftec, such as for example Kraton SEBSG1657MS.

The SEBS copolymer surprisingly reduces the negative impact of forexample EPS or PET, on the mechanical properties of the polymercomposition, such as for example the impact strength.

The SEBS is present between 0.1-10 wt %, preferably 0.1-8 wt %, morepreferably 1-4 wt %, more preferably between 0.2-3 wt %, more preferablybetween 0.3-2 wt %, most preferably 0.4-1.5 wt %, within the polymercomposition.

Additives

The polymer composition can further comprise between 0.05-10 wt %,preferably 0.1-8 wt %, of additives, within the polymer composition.

Additives comprise stabilizers, peroxides. calcium oxides (CaO), EBAwax, pigment binders, talc or colorants.

A stabilizer can be added, such as for example masterbatches like TosafME 833848, which is a blend of about 70 wt % Low-Density Polyethylene(LDPE) with a phenolic stabilizer and an Irgafos. The stabilizer maypreferably be added to the polymer composition between 0-4 wt %, morepreferably between 0.1-1.5 wt %. Further examples of stabilizers areExxelor PEI040 and Irganox B225.

A peroxide, in the form of an organic compound or masterbatch can beadded. The peroxide improves the flow of the material. The peroxide canfor example be selected from the group of Zebraflow T028, ZebraflowT0214 or Zebraflow T0318. The peroxide can for example be used toshorten the polymer chains thereby lowering viscosity and improving flowof the polymer composition. Between 0-2 wt % of a masterbatch can forexample be added, such a masterbatch can contain for example between2-10 wt % of a suitable peroxide. The peroxide can preferably be addedto the polymer composition between 0-4 wt %, more preferably between0.05-1.5 wt %.

A calcium oxide (CaO) can be added to inhibit release of HCl. The CaOcan for example be added as a masterbatch with for example LDPE. Anexample of a CaO suitable for the invention Is W&R Master Desiccant60003. CaO can preferably be added in a range between 0-4 wt %, morepreferably between 0.05-2 wt %, most preferably 0.1-1.5 wt %.

A pigment binder can preferably be added between 0-4 wt %, morepreferably between 0.1-1.5 wt %. For example, a PE-maleic anhydride canbe added as a pigment binder to the polymer composition between 0.1-2 wt%, preferably between 0.2-1 wt %, more preferably between 0.5-1 wt %.

Talc can be added, an example of suitable talc is Steamic OOSd.

A black colorant can preferably be added to the polymer compositionbetween 0.1-5 wt %, more preferably between 1-2 wt % in the form of amasterbatch blend.

Ash

The ash content of the polymer composition may for example be between4-8 wt %.

Composition

The composition according to the present invention has surprisingly goodmechanical properties.

The polymer composition has preferably a melt flow rate MFR (230° C.,2.16 kg) of between 5-25 g/10 min, more preferably between 12-18 g/10min.

The polymer composition has preferably a modulus ranging between600-1300 MPa, more preferably between 700-1200 MPa.

The polymer composition preferably has a Charpy notched impact strengthof between 20-60 kJ/m², preferably 23-50 kJ/m², more preferably between25-35 kJ/m², more preferably between 22-55 kJ/m², most preferably 26-51determined using ISO 179-1eA:2010.

The composition according to the present invention can fulfil the ISO14021:2016 standard and label as Type II environmental using ISO14021:2016.

Process

The invention further relates to a process for preparing the polymercomposition of the invention.

This process comprises the steps of

-   -   a) treating a mixed polyolefin recyclate fraction with water        without added thermal energy;    -   b) treating the solution obtained mixed polyolefin recyclate        fraction from a) in a washing step with an alkaline medium at a        temperature of at least 60° C.;    -   c) sorting of the mixed polyolefin recyclate fraction solution        obtained from b) obtaining a PE recyclate and/or mixed PP        recyclate fraction, wherein steps a) and b) can also be carried        out in the reverse order;    -   d) treating the PE recyclate and/or mixed PP recyclate fraction        solution obtained from the above steps at a temperature in the        range of between 50-155° C., preferably for a period of at least        60 minutes.    -   e) adding the dried PE recyclate and/or mixed PP recyclate        fraction obtained from step d) to an extruder with the addition        of the POE and SEBS; optionally additives; wherein the mix Is        processed to obtain a recycled PP and recycled PE material.    -   wherein step e) is conducted between 200-250° C., preferably        between 210-240° C., more preferably between 220-230° C. for        between 1-10 minutes.

The process of making the polymer composition may comprise compoundingand extruding.

The process of making the polymer composition may use a co-rotating twinscrew tandem extruder to which the recycled polypropylene, recycledpolyethylene, styrene ethylene butylene styrene block copolymer andpolyolefin elastomer, and optionally additives are added.

Additives can be added in a reclaim extruder (first extruder) and acompounding extruder (second extruder) of a tandem extruder.

Articles

The polymer composition can be presented in granule or flake form to beused for manufacturing articles.

The polymer composition of recycled PP and recycled PE is suitable formanufacturing products for long-term use, such as for example boxes,trays, paint pails or consumer goods.

The articles made from the polymer composition are preferably formed byinjection moulding.

Embodiments

In a preferred embodiment the polymer composition comprises 60-80 wt %of a recycled polypropylene, 10-35 wt % of a recycled polyethylene, 5-20wt % of a polyolefin elastomer (POE) and 0.1-4 wt % styrene ethylenebutylene styrene block copolymer (SEBS), wherein said polymercomposition comprises at least 11 wt % of polyolefin elastomer andstyrene ethylene butylene styrene block copolymer.

In another embodiment the polymer composition comprises 62-75 wt % of arecycled polypropylene, 10-35 wt % of a recycled polyethylene, 5-20 wt %of a polyolefin elastomer (POE) and 0.1.4 wt % styrene ethylene butylenestyrene block copolymer (SEBS), wherein said polymer compositioncomprises at least 11 wt % of polyolefin elastomer and styrene ethylenebutylene styrene block copolymer.

In another embodiment the polymer composition comprises 62-75 wt % of arecycled polypropylene, 15-25 wt % of a recycled polyethylene, 5-20 wt %of a polyolefin elastomer (POE) and 0.1-4 wt % styrene ethylene butylenestyrene block copolymer (SEBS), wherein said polymer compositioncomprises at least 11 wt % of polyolefin elastomer and styrene ethylenebutylene styrene block copolymer.

In another embodiment the polymer composition comprises 62-75 wt % of arecycled polypropylene, 15-25 wt % of a recycled polyethylene, 6-15 wt %of a polyolefin elastomer (POE) and 0.5-1.5 wt % styrene ethylenebutylene styrene block copolymer (SEBS), wherein said polymercomposition comprises at least 11 wt % of polyolefin elastomer andstyrene ethylene butylene styrene block copolymer.

In another embodiment the polymer composition comprises 60-80 wt % of arecycled polypropylene, 10-35 wt % of a recycled polyethylene, 6-15 wt %of a polyolefin elastomer (POE) and 0.5-1.5 wt % styrene ethylenebutylene styrene block copolymer (SEBS), wherein said polymercomposition comprises at least 11 wt % of polyolefin elastomer andstyrene ethylene butylene styrene block copolymer.

In another embodiment the polymer composition Is preferably used forinjection moulding of articles.

The polymer composition according to the invention may further compriseoptional components different from the previously mentioned componentsof the polymer composition, such as additives, wherein the total of thepreviously mentioned components and the optional components is 100 wt %of the total polymer composition.

Accordingly, the invention relates to a polymer composition consistingof the previously mentioned components and the optional components.

It Is noted that the invention relates to all possible combinations offeatures described herein, preferred in particular are thosecombinations of features that are present in the claims. It willtherefore be appreciated that all combinations of features relating tothe polymer composition according to the invention; all combinations offeatures relating to the process according to the invention and allcombinations of features relating to the polymer composition accordingto the invention and features relating to the process according to theinvention are described herein.

It is further noted that the term ‘comprising’ does not exclude thepresence of other elements. However, it is also to be understood that adescription on a product/polymer composition comprising certaincomponents also discloses a product/polymer composition consisting ofthese components. The product/polymer composition consisting of thesecomponents may be advantageous in that it offers a simpler, moreeconomical process for the preparation of the product/polymercomposition. Similarly, it is also to be understood that a descriptionon a process comprising certain steps also discloses a processconsisting of these steps. The process consisting of these steps may beadvantageous in that it offers a simpler, more economical process.

When values are mentioned for a lower limit and an upper limit for aparameter, ranges made by the combinations of the values of the lowerlimit and the values of the upper limit are also understood to bedisclosed.

The invention is now elucidated by way of the following examples,without however being limited thereto.

Examples

Quality Testing and Standards

For quality testing samples are taken during processing and from the endproduct. The Melt Mass-Flow Rate (MFR) is measured at day 3 and day 10of ageing.

The MFR and Melt Volume-Flow Rate (MVR) are assessed using the ISO1133-1:2011, 2.16 kg, T=230° C. For POE and PE, the MFR and MVR areassessed using the ISO 1133-1:2011 at 190° C. under 2.16 kg.

The color of the product during and at the end of the process isidentified using the CIELAB (L, a*, b*). L* identifies the amount oflight versus dark; a* refers to red-green and b* refers to blue-yellow.These are parameters standardized by the International Commission forIllumination (CIE) in 1976 and known as CIELAB.

The cold xylene solubles (CXS) is measured using the ISO 16152:2005,T=25° C.

The ash content of the polymer composition or product is measured usingthe ISO3451-1 2008.

The density of the polymer composition or product is measured using theISO 1183-1:2019, T=23° C., tensile bar.

The tensile strength/test of the polymer composition or product ismeasured using the ISO 527-1A:2012, T=23° C., 11.

The flexural of the polymer composition or product is measured using theISO 178:2010, T=23° C., II.

The tensile bar test of the moulded articles from the polymercomposition or product is measured using the ISO 527-1A′2012.

The Charpy of the moulded articles from the polymer composition orproduct is measured using the ISO 179-1eA:2010 (T=−20° C. and T=23° C.,11, moulded bar 527/1A-notched) and ISO 179-1eA:2010 (T=−20° C. mouldedbar 527/1A-unnotched).

Extrusion products and injection-moulded articles are produced andassessed following ISO19069-2:2016, ISO294-1:2017 and ISO294-3:2002.

Product Examples

A polymer composition of a recycled PP and HDPE were prepared.

POE used was Infuse 9077

As stabilizer 0.75 wt % TOSAF was used.

As CaO a masterbatch containing 70 wt % CaO was used (particle size <10μm).

EXPP152A and EXPP163A are recycled PP, according to DSD 324 standard.

HDPE54040216 is a recycled HDPE according the DSD 329 standard(April/2009).

DOW Infuse 9077 is a POE.

Kraton G1657 MS is a SEBS rubber.

TABLE 1 Polymer composition of recycled PP and recycled PE and theirmain properties Sample Ex1 Ex2 Ex3 Ex4 Ex5 Ex6 Ex7 CE1 CE2 EXPP152A(MFR67.6 67.1 42.00 76.80 42.00 66.8 67.2 15)/300P EXPP163A(MFR 29.80 34.8099.6 99.6 50)/300T HDPE 5404 0216 20 20 10 10 10 19 20 DOW Infuse 907710 10 5 5 5 10 10 Kraton G1657MS 2 2 8 8 8 1.5 1.5 Irganox 8225 0.2 0.20.10 0.10 0.10 0.20 0.2 EBA wax 0.2 0.2 0.10 0.10 0.10 0.20 0.2 SteamicOOSd 5 (talc) Exxelor PE1040 0.5 DOW Infuse 9107 Tosaf ME 0.75 0.75833848 Peroxide 0.3 0.3 CaO 0.5 0.5 Aging before 14 14 14 14 14 14 14testing days Density ISO 1183 (T = 23° C.) Density Average 920 921 936915 913 915 915 915 919 kg/m³ Melt Flow ISO 1133 (I 2, 16; 230 C.) MFRg/10 min 18 17 16.7 11.5 16.8 15.0 15.0 16.7 51 MVR ml/10 min 24 23 21.715.5 22.4 22.8 68 Melt density g/ml 0.770 0.742 0.750 Ash Content % 1.431.38 5.25 1.12 1.11 1.24 1.41 Charpy ISO 179/1eA (T = 23° C., II)moulded bar 527/1A Breaktype (B/O/T) 5 × P 5 × P 5 × P Hammer Type 2 J 2J 2 J Charpy impact 41.6 46.7 50.77 49.58 48.62 30 30 5.21 4.1 kJ/m²Charpy ISO 179/1eA (T = −20° C., II) moulded bar 527/1A Breaktype(B/O/T) 5 × C 5 × C 5 × C Hammer Type 0.5 J 0.5 J 0.5 J Charpy impact7.6 8.1 5.42 5.53 6.33 1.85 2.0 kJ/m² Tensile ISO 527/1A (T = 23° C.,II) E-Modulus (Chord 787 800 1001 885 852 800 800 1259 1247 0.05%-0.25%)N/mm² Tensile Strain at 47.2 48.2 62.2 219.4 69.4 27.9 16.9 Break(Elongation at Break) % Tensile Strain at 10.2 10.0 10.0 11.8 10.5 9.17.1 Yield (Elongation at yield) % Tensile stress at 12.4 11.8 13.8 12.313.9 4.8 18.6 Break N/mm² Tensile strength 19.7 20.4 19.6 N/mm² YieldStress N/mm² 18.7 18.6 19.7 20.4 19.6 27.9 26.8 Flexural ISO 178 (T =23° C., II) Flexural modulus 790 800 1010 850 847 1210 1220 (secant) MpaFlexural strength 19.8 20.2 23.1 22.2 21.8 32.4 32.7 MPa Weight oftestbar Weight g 26.9 26.0 26.1 Sample CE3 CE4 CE5 CE6 CE7 CE8 CE9 CE10EXPP152A(MFR 15)/300P 89.6 69.6 75.80 80.80 46.00 79.6 79.60EXPP163A(MFR 50)/300T 79.6 34.80 HDPE 5404 0216 20 20 10 10 10 10 10 DOWInfuse 9077 10 10 5 5 5 5 Kraton G1657MS 4 4 4 Irganox 8225 0.2 0.2 0.20.10 0.10 0.10 0.20 0.20 EBA wax 0.2 0.2 0.2 0.10 0.10 0.10 0.20 0.20Steamic OOSd (talc) 5 5 5 Exxelor PE1040 DOW Infuse 9107 5 Tosaf ME833848 Peroxide CaO Aging before testing days 14 14 14 14 14 14 14 14Density ISO 1183 (T = 23° C.) Density Average kg/m³ 926 912 919 942 915915 951 951 Melt Flow ISO 1133 (I 2, 16; 230 C.) MFR g/10 min 29 37.4 1711.5 11.6 17.0 10.9 10.9 MVR ml/10 min 39 50.1 23 15.3 15.6 22.7 14.514.5 Melt density g/ml 0.752 0.744 0.749 0.757 0.757 Ash Content % 1.521.31 1.40 5.91 1.15 1.23 6.25 6.25 Charpy ISO 179/1eA (T = 23° C., II)moulded bar 527/1A Breaktype (B/O/T) 5 × C 5 × C 5 × C 5 × C 5 × CHammer Type 1 J 1 J 1 J 2 J 2 J Charpy impact kJ/m² 4.0 7.82 15.5 12.8213.24 14.39 8.31 8.31 Charpy ISO 179/1eA (T = −20° C., II) moulded bar527/1A Breaktype (B/O/T) 5 × C 5 × C 5 × C 5 × C 5 × C Hammer Type 0.5 J0.5 J 0.5 J 2 J 2 J Charpy impact kJ/m² 2.1 3.64 7.1 3.88 4.38 5.42 2.732.73 Tensile ISO 527/1A (T = 23° C., II) E-Modulus (Chord 0.05%- 11691044 838 1172 967 944 1343 1343 0.25%) N/mm² Tensile Strain at Break 5.349.4 39.8 22.3 92.5 51 92.1 92.1 (Elongation at Break) % Tensile Strainat Yield 5.1 7.1 9.4 9.3 10.1 9.4 8.6 8.6 (Elongation at yield) %Tensile stress at Break 23.4 14.0 12.4 11.8 11.4 14.3 7 7 N/mm² Tensilestrength N/mm² 22.3 22.0 21.1 24.2 24.2 Yield Stress N/mm² 23.5 22.019.2 22.3 22.0 21.1 24.2 24.2 Flexural ISO 178 (T = 23° C., II) Flexuralmodulus (secant) 1160 1000 834 1120 915 912 1320 1320 Mpa Flexuralstrength MPa 29.8 26.8 21.0 26.0 24.1 23.5 30 30 Weight of testbarWeight g 26.9 26.1 26.1 27.0 27.0

What is claimed is:
 1. A process for preparing a polymer composition comprising 60-80 wt. % of a recycled polypropylene (PP); 10-35 wt. % of a recycled polyethylene (PE); 5-20 wt. % of a polyolefin elastomer (POE); 0.1-10 wt. % styrene ethylene butylene styrene block copolymer (SEBS), wherein the wt. % is relative to the total weight of the polymer composition; wherein said polymer composition comprises at least 11 wt. % of polyolefin elastomer and styrene ethylene butylene styrene block copolymer, the process comprising the steps of: collecting the recycled polypropylene according to a DSD 324 or DSD 324-1 standard, collecting the recycled polyethylene according to a DSD 329 standard, mixing the recycled polypropylene, the recycled polyethylene, the POE and the SEBS to obtain the polymer composition.
 2. The process according to claim 1, wherein the polymer composition comprises <0.5% by mass expanded polystyrene.
 3. The process according to claim 2, comprising: 60-77.5 wt. % of a recycled polypropylene; 12-35 wt. % of a recycled polyethylene; 6-20 wt. % of a polyolefin elastomer (POE); 0.1-8 wt. % styrene ethylene butylene styrene block copolymer (SEBS).
 4. The process according to claim 1, wherein the recycled PP content of the polymer composition is made-up of between 25-75 wt. % BOPP and between 25-75 wt. % rubber-containing injection moulded material and wherein wt. % is relative to the total amount of recycled PP.
 5. The process according to claim 1, wherein the recycled PP is present between 60-80 wt. % within the polymer composition; wherein wt. % is relative to the total weight of the polymer composition.
 6. The process according to claim 1, wherein the recycled PE comprises recycled High-Density Polyethylene (HDPE) to at least 90 wt. % and wherein the recycled PE has a density in the range of 0.94-0.97 g/cm³.
 7. The process according to claim 1, wherein the recycled PE has a MFR 2.16 kg, 230° C. (g/10 min) of between 0.4-0.9 and a MVR 2.16 kg, 230° C. (m/10 min) of between 0.3-1.3 and wherein the recycled PE is present between 10-35 wt. %, within the polymer composition, wherein wt. % is relative to the total weight of the polymer composition.
 8. The process according to claim 1, wherein the recycled PE is present in the polymer composition at a weight ratio between of 3:1-1:1 with the POE.
 9. The process according to claim 1, wherein the polymer composition has a total rubber content of between 5-24 wt. % as determined with cold xylene solubles (CXS).
 10. The process according to claim 1, wherein the POE used in the Invention comprises an ethylene (C2) octene (C8) metallocene rubbers with a blocky structure.
 11. The process according to claim 1, wherein The POE has a density of between 0.85-0.89, an MFR of between 0.3-1, and wherein the POE is present at between 5-20 wt. %, within the polymer composition.
 12. The process according to claim 1, wherein the composition has a Charpy notched impact strength of between 20-60 kJ/m² determined using ISO 179-1:eA2010.
 13. The process according to claim 5, wherein the recycled PP is present between 60-77.5 wt. % within the polymer composition.
 14. The process according to claim 6, wherein the recycled PE comprises recycled High-Density Polyethylene (HDPE) to at least 92 wt. %.
 15. The process according to claim 9, wherein the polymer composition has a total rubber content of between 8-20 wt. % as determined with cold xylene solubles (CXS).
 16. The process according to claim 12, wherein the composition has a Charpy notched Impact strength of between 22-55 kJ/m² determined using ISO 179-1:eA2010.
 17. The process according to claim 13, wherein the recycled PP is present between 62-75 wt. %, within the polymer composition.
 18. The process according to claim 14, wherein the recycled PE comprises recycled High-Density Polyethylene (HDPE) to at least 95 wt. %.
 19. The process according to claim 15, wherein the polymer composition has a total rubber content of between 11-18 wt. %, as determined with cold xylene solubles (CXS).
 20. The process according to claim 16, wherein the composition has a Charpy notched impact strength of between 26-51 determined using ISO 179-1:eA2010. 